WO2025029437A1

WO2025029437A1 - Strapping device with auto-shutoff features

Info

Publication number: WO2025029437A1
Application number: PCT/US2024/037328
Authority: WO
Inventors: Andreas Keller
Original assignee: Signode Industrial Group LLC
Current assignee: Signode Industrial Group LLC
Priority date: 2023-07-28
Filing date: 2024-07-10
Publication date: 2025-02-06
Anticipated expiration: 2026-01-28

Abstract

Various embodiments of the present disclosure provide a strapping device including a rocker movable between a home position and a strap-insertion position, a rocker mover, a motor operably connected to the rocker mover and configured to move the rocker mover, and a controller operably connected to the motor and configured to control the motor. The controller is configured to, responsive to an opening condition being met: control the motor to begin moving the rocker mover and, responsive to the earlier of a first shut-off condition being met and a tool-opened condition being met, control the motor to stop moving the rocker mover.

Description

STRAPPING DEVICE WITH AUTO-SHUTOFF FEATURES

Priority

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/516,203, filed July 28, 2023, and U.S. Provisional Patent Application No. 63/553,360, filed February 14, 2024, the entire contents of both of which are incorporated herein by reference.

Field

[0002] The present disclosure relates to strapping devices, and more particularly to strapping devices configured to tension strap around a load and to attach overlapping layers of the strap to one another to form a tensioned strap loop around the load.

Background

[0003] Strapping tools are configured to tension strap around a load and to attach overlapping layers of the strap to one another to form a tensioned strap loop around the load. Many strapping tools utilize friction welding to attach overlapping upper and lower strap layers to one another. To use one of these strapping tools to form a tensioned strap loop around a load, an operator pulls strap leading end first from a strap supply, wraps the strap around the load, and positions a lower layer of the strap including the leading end of the strap below an upper layer of the strap. The operator introduces the overlapped strap layers into the strapping tool and presses a button to initiate a tensioning process during which a tension wheel rotates to move the upper strap layer over the lower strap layer and tension the strap around the load. After completion of the tensioning process, a sealing process is initiated. During the sealing process, a toothed weld shoe forces the strap layers against a toothed weld plate. A motor oscillates the weld shoe at a high frequency as the weld shoe exerts a welding force on the strap layers. The oscillating weld shoe oscillates the upper strap layer relative to the lower strap layer, which generates friction between portions of the overlapping strap layers that locally melts them. The motor stops oscillating the weld shoe while the weld shoe continues to exert the welding force. The melted portions of the overlapping strap layers join together and solidify as they cool, thereby attaching the upper and lower strap layers to form the tensioned strap loop.

Summary

[0004] Various embodiments of the present disclosure provide a strapping device including a rocker movable between a home position and a strap-insertion position, a rocker mover, a motor operably connected to the rocker mover and configured to move the rocker mover, and a controller operably connected to the motor and configured to control the motor. The controller is configured to, responsive to an opening condition being met control the motor to begin moving the rocker mover and, responsive to the earlier of a first shut-off condition being met and a tool-opened condition being met, control the motor to stop moving the rocker mover.

Brief Description of the Figures

[0005] Figures 1A and IB are perspective views of one example embodiment of a strapping device of the present disclosure.

[0006] Figure 1C is a block diagram of certain components of the strapping device of Figures 1A and IB.

[0007] Figures 2A-2C are diagrammatic views of the strapping device of Figures 1A and IB securing a load to a pallet.

[0008] Figure 2D is a perspective view of a friction- weld strap joint formed by the strapping device of Figures 1A and IB to attach two overlapping layers of strap.

[0009] Figures 3A and 3B are perspective views of the working assembly of the strapping device of Figures 1A and IB.

[0010] Figure 4A is a perspective view of the tensioning assembly of the working assembly of Figures 3A and 3B.

[0011] Figure 4B is an exploded perspective view of the tensioning assembly of Figure 4A.

[0012] Figure 4C is a cross-sectional perspective view of the tensioning assembly of Figure 4A taken along line 4C-4C of Figure 4A. [0013] Figure 4D is a front elevational view of the rocker mover of the tensioning assembly of Figure 4A.

[0014] Figure 5A is a perspective view of the decoupling assembly of the working assembly of Figures 3A and 3B.

[0015] Figure 5B is an exploded perspective view of the decoupling assembly of Figure 5A.

[0016] Figure 5C is a cross-sectional perspective view of the decoupling assembly of Figure 5 A taken along line 5C-5C of Figure 5 A.

[0017] Figures 6A and 6B are perspective views of the actuating assembly of the working assembly of Figures 3A and 3B.

[0018] Figures 7A and 7B are perspective views of the cam-engaging assembly of the working assembly of Figures 3 A and 3B.

[0019] Figures 7C and 7D are side views of the cam-engaging assembly of Figures 7A and 7B with the cam engager in its home and actuated positions, respectively.

[0020] Figures 8A-8G are side views of part of one side of the working assembly of Figures 3A and 3B showing the tensioning assembly moving from a home position to a strapinsertion position and from the strap-insertion position to a tensioning position after strap is inserted into the strapping device. Certain components of the working assembly are not shown for clarity.

[0021] Figures 9A-9G are side views of part of the opposite side of working assembly of Figures 3 A to 3B that correspond to Figures 8A-8G. Certain components of the working assembly are not shown for clarity.

[0022] Figures 10A-10D are side views similar to Figures 9A-9G showing a scenario in which a cam of the rocker mover of Figure 4D is in the path of the cam-engaging finger of the cam-engaging assembly of Figures 7A and 7B.

[0023] Figures 11A-11C are side views similar to Figures 9A-9G showing a scenario in which the cam-engaging finger of the cam-engaging assembly of Figures 7A and 7B is in the rotational path of a cam of the rocker mover of Figure 4D but does not extend across the rotational path.

[0024] Figure 12 is a side view of part of the strapping device of Figures 1A and IB with certain components removed to show first, second, and third sensors. [0025] Figure 13 is a flowchart showing one example embodiment of an opening process of the present disclosure.

[0026] Figure 14 is a flowchart showing one example embodiment of a tensioning process of the present disclosure.

Detailed Description

[0027] While the systems, devices, and methods described herein may be embodied in various forms, the drawings show and the specification describes certain exemplary and nonlimiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connections of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as mounted, connected, etc., are not intended to be limited to direct mounting methods but should be interpreted broadly to include indirect and operably mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

[0028] Figures 1A-12 show one example embodiment of a strapping device of the present disclosure in the form of a battery-powered portable strapping device 50 and certain assemblies and components thereof. As shown in Figures 2A-2C, the strapping device 50 is configured to carry out a strapping process to tension and seal strap S (plastic strap in this example embodiment) around a load L on a pallet P to form a tensioned strap loop that secures the load L to the pallet P. An operator pulls strap S from a strap supply (not shown) and wraps the strap around the load L and through the openings in the pallet P until a lower layer LL of the strap S (which includes the leading end of the strap S) is positioned below an upper layer UL of the strap S, as shown in Figure 2A. The operator then introduces the overlapped upper and lower layers UL and LL of the strap S into the strapping device 50 and actuates one or more buttons to initiate the strapping process. As shown in Figure 2B, a motor drives a tensioning assembly to carry out a tensioning process during which the strapping device 50 tensions strap S around the load L. Once a preset tension is reached in the strap S, as shown in Figure 2C, the motor drives a sealing assembly to carry out a sealing process during which the strapping device 50 connects the upper and lower layers UL and LL of the strap S to one another via friction welding to form a strap joint SJ, as shown in Figure 2D, and cuts the strap S from the strap supply.

[0029] The strapping device 50 includes a housing 100, a working assembly 200, a cover 1300, first and second pushbutton actuators 1410 and 1440, a display assembly 1490C), a power supply 1500, a controller 1600, and one or more sensors 1700.

[0030] The housing 100, which is shown in Figures 1A and IB, is formed from multiple components (not individually labeled) that collectively at least partially enclose and/or support some (or all) of the other assemblies and components of the strapping device 50. In this example embodiment, the housing 100 includes a front housing section 110, a rear housing section 120, a motor housing section 130, and a handle section 150. The front housing section 110 at least partially encloses and/or supports at least some of the components of the working assembly 200. The rear housing section 120 at least partially encloses and/or supports at least some of the components of the display assembly 1490 and defines a receptacle sized, shaped, and otherwise configured to receive and at least partially enclose and/or support the power supply 1500 and the controller 1600. The motor housing section 130 extends between and connects the bottoms of the front and rear housing sections 110 and 120 and at least partially encloses and/or supports at least some of the components of the working assembly 200, including the motor 1100. The handle housing section 150 extends between and connects the tops of the front and rear housing sections 110 and 120 and defines a handle sized and shaped to be held by a hand of the operator. This is merely one example, and in other embodiments the components of the strapping device may be supported and/or enclosed by any suitable portion of the housing 100. The housing 100 may be formed from any suitable quantity of components joined together in any suitable manner. In this example embodiment, the housing 100 is formed from plastic, though it may be made from any other suitable material in other embodiments. The cover 1300 is attached to the front housing section 110 and covers part of the working assembly 200. [0031 ] The working assembly 200, which is best shown in Figures 3 A and 3B, includes the majority of the components of the strapping device 50 that are configured to carry out the opening process to prepare the strapping device 50 to receive strap and the strapping process to tension the strap around the load, attach the overlapping layers of the strap to one another, and cut the strap from the strap supply. The working assembly 200 includes a support 300, a tensioning assembly 400, a decoupling assembly 500, an actuating assembly 600, a camengaging assembly 700, a sealing assembly 900, a transmission 1000, and a motor 1100.

[0032] The support 300, which is best shown in Figures 3A and 3B, serves as a direct or indirect common mount for the tensioning assembly 400, the decoupling assembly 500, the actuating assembly 600, the cam-engaging assembly 700, the sealing assembly 900, the transmission 1000, and the motor 1100. The support 300 includes a base 300b and a frame 300f extending from the base 300b. The base 300b supports a toothed tension plate 312 below the tension wheel 400w of the tensioning assembly 400 (described below) and a toothed weld plate 314 below the weld shoe 912 of the sealing assembly 900 (described below).

[0033] The tensioning assembly 400, which is best shown in Figures 4A-4D, is operable (with the motor 1100) to move the tensioning assembly 400 relative to the support 300 during the opening process and to tension the strap around the load during the tensioning process. The tensioning assembly 400 includes a rocker 400r, a rocker cover 400c, tensioningassembly gearing, and a tension wheel 400w driven by the tensioning-assembly gearing. The tension wheel 400w is supported by the tensioning-assembly gearing, which is in turn supported by the rocker 400r.

[0034] The tensioning-assembly gearing includes: a driven shaft 410; a tensioningassembly freewheel 412; a first set of planet gears 414a, 414b, and 414c; a gear cover 415; a rocker mover 420; a rollback ring gear 430; a rollback intermediate gear 431; a carrier 432; a second set of planet gears 434a, 434b, 434c, and 434d; a third set of planet gears 436a, 436b, and 436c; and bearings 405b 1, 405b2, 405b3, and 405b4. Certain components of the tensioningassembly gearing are centered on, and certain components of the tensioning-assembly gearing are rotatable about, a tension-wheel rotational axis A4oow. The driven shaft 410 includes a shaft portion 410a having a driven end 410al and a first sun gear 410b at the end opposite the driven end 410al. The first set of planet gears 414a-414c are rotatably mounted (such as via respective bearings and mounting pins) to the rocker cover 400c and secured in place via the gear cover 415. The rollback ring gear 430 includes internal teeth 43 Oit and external teeth 430ot. The carrier 432 includes a planet-gear carrier 432a to which the second set of planet gears 434a-434d are rotatably mounted (such as via respective bearings and mounting pins) and a second sun gear 432b rotatable with (and here integrally formed with) the planet-gear carrier 432a about the tension-wheel rotational axis A400W. The third set of planet gears 436a-436c are rotatably mounted to the rocker 400r (such as via respective bearings and mounting pins).

[0035] The rocker mover 420, which is best shown in Figure 4D, includes a ring gear 421 having internal teeth 42 lit and supporting an annular cam support 422 that includes angularly spaced, triangularly shaped first, second, and third cams 424, 426, and 428. The first cam 424 has a leading end 4241e and a trailing end 424te connected by a convexly curved fingerengaging surface 424s and a concavely curved lower surface. The finger-engaging surface 424s has an apex 424s’ that corresponds to the point on the finger-engaging surface 424s furthest from the center of the cam support 422. The apex 424s’ of the finger-engaging surface 424s is a distance Rmax from the center of the cam support 422, the leading end 4241e of the cam 424 is a distance Rie from the center of the cam support 422, and the trailing end 424te of the cam 424 is a distance Rte from the center of the cam support 422. Rmax is greater than Rie and Rte such that the apex 424s’ is further from the center of the cam support 422 than the leading and trailing ends 4241e and 424te. In this example embodiment, Rte is greater than Rie though the opposite may be true or they may be the same in other embodiments.

[0036] The portion of the finger-engaging surface 424s extending between the leading end 4241e and the apex 424s’ is substantially planar such that the distance between the finger-engaging surface 424s and the center of the cam support 422 increases at a substantially constant rate moving from the leading end 4241e to the apex 424s’. The portion of the fingerengaging surface 424s extending between the apex 424s’and the trailing end 424te is curved such that the distance between the finger-engaging surface 424s and the center of the cam support 422 decreases moving from the apex 424s’ to the trailing end 424te. The second and third cams 426 and 428 are identical to the first cam 424 and are not separately described for brevity. Their components are identified herein with similar numbers as the components of the first cam 424, with the leading “424” being replaced with “426” and “428,” respectively. The first, second, and third cams 424, 426, and 428 are equally angularly spaced apart such that each cam is spaced apart from the others by the same angle a, which is 120 degrees in this example embodiment. While the rocker mover includes three cams in this example embodiment, it may include any suitable quantity of one or more cams in other embodiments.

[0037] The shaft portion 410a of the driven shaft 410 extends through and is engaged by the tensioning-assembly freewheel 412, which is itself supported by and positioned within a bore defined through the cover 400c, which is attached to the rocker 400r. The tensioning-assembly freewheel 412 is configured to permit rotation of the driven shaft 410 relative to the rocker 400r in a tensioning rotational direction T — referred to as the tensioning direction T — and to prevent rotation of the driven shaft 410 in a rollback direction TREV, which is the rotational direction opposite the tensioning direction T. The first sun gear 410b of the driven shaft 410 meshes with and drivingly engages the first set of planet gears 414a-414c. The first set of planet gears 414a-414c mesh with the internal teeth 42 lit of the ring gear 421 of the rocker mover 420. The bearing 405b 1 rotatably supports the rocker mover 420 and separates it from the rocker 400r and the cover 400c. The first sun gear 410b of the driven shaft 410 extends through the gear cover 415 and meshes with and drivingly engages the second set of planet gears 434a- 434d. The second set of planet gears 434a-434d mesh with the internal teeth 430it of the rollback ring gear 430. The bearing 405b2 rotatably supports the carrier 432 such that the carrier 432 is rotatable relative to the rocker 400r. The second sun gear 432b of the carrier 432 meshes with and drivingly engages the third set of planet gears 436a-436c. The tension wheel 400w is rotatably mounted to the rocker 400r via bearings 405b3 and 405b4 such that the third set of planet gears 436a-436c mesh with internal teeth (not labeled) of the tension wheel 400w and therefore drivingly engage the tension wheel 400w. The tension wheel 400w is held in place longitudinally (in the direction of the tensioning-wheel axis A4oow) via a suitable retainer and suitable fasteners (not shown for clarity).

[0038] The tensioning assembly 400 is movably mounted to the support 300 via the rocker 400r and a tensioning-assembly mounting shaft 395 (Figures 3A and 3B) and configured to pivot relative to the support 300 — and particularly relative to the base 300b of the support 300 — under control of the motor 1100 (as described below) and about a rocker-pivot axis A4oor among a home position (Figures 8A-8C), a strap-insertion position (Figures 8D-8F), and a tensioning position (Figure 8G). When the tensioning assembly 400 is in the home position, the tension wheel 400w is adjacent to the tension plate 312 of the support 300. When the tensioning assembly 400 is in the strap-insertion position, the tension wheel 400w is spaced-apart from the tension plate 312 to enable the overlapping upper and lower layers of the strap to be inserted between the tension wheel 400w and the tension plate 312. When the tensioning assembly 400 is in the tensioning position and overlapping strap layers are between the tension wheel 400w and the tension plate 312, the tension wheel 400w engages the upper layer of strap and forces the strap layers onto the tension plate 312. The weight of the tensioning assembly 400 and one or more springs or other biasing elements (not shown) bias the tensioning assembly 400 to the home position.

[0039] Specifically, the tensioning-assembly mounting shaft 395 extends through openings defined through the frame 300f of the support 300 and openings defined through first and second mounting ears 400rl and 400r2 of the rocker 400r. The rollback intermediate gear 431 is rotatably mounted to the tensioning-assembly mounting shaft 395 and positioned between the mounting ears 400rl and 400r2 of the rocker 400r such that teeth of the rollback intermediate gear 431 mesh with the external teeth 430ot of the rollback ring gear 430.

[0040] The decoupling assembly 500, which is best shown in Figures 5A-5C, controls whether the rollback ring gear 430 can rotate about the tensioning-wheel axis A ow. When the decoupling assembly 500 is in a coupled configuration, the decoupling assembly 500 prevents the rollback ring gear 430 from rotating about the tensioning- wheel axis A400W, which enables the motor 1100 to drive the tension wheel 400w to tension the strap and enables the tension wheel 400w to hold tension in the strap after the tensioning process is complete. Conversely, when the decoupling assembly 500 is in a release configuration, the rollback ring gear 430 is rotatable about the tensioning-wheel axis A400W such that the tension wheel 400w can release the held tension. The decoupling assembly 500 includes a decoupling-assembly shaft 510, a first engageable element 520, a second engageable element 530, an expandable element 540, a sleeve 550, a threaded fastener 560, a spacer 570, and a gear 580.

[0041] The decoupling-assembly shaft 510 includes a body 512 having a first end 512a having an irregular cross-section and second end 512b having radially extending teeth around its circumference. A first support 514 extends from the first end 512a. The first engageable element 520 comprises a tubular bushing having a cylindrical outer surface and an interior surface having a perimeter that matches the perimeter of the first end 512a of the body 512 of the decoupling-assembly shaft 510. The second engageable element 530 includes a tubular body 532 and an annular flange 534 at one end of the body 532. An opening 534o is defined through the flange 534. The expandable element 540 includes a torsion spring having a first end 540a and a second end 540b. The sleeve 550 includes a tubular body 552 having teeth 554 extending around its outer circumference. The body 552 defines an opening 554o.

[0042] As best shown in Figure 5C, the first engageable element 520 is mounted on the first end 512a of the body 512 of the decoupling-assembly shaft 510 for rotation therewith about a decoupling-assembly rotational axis Asoo. The second engageable element 530 circumscribes the first support 514 of the body 512 of the decoupling-assembly shaft 510 and is positioned such that the body 532 is adjacent and coaxial with the first engageable element 520. The expandable element 540 circumscribes the first engageable element 520 and the body 532 of the second engageable element 530. The outer diameters of the first engageable element 520 and the body 532 of the second engageable element 530 are substantially the same and are equal to or larger than the resting inner diameter of the expandable element 540. This means that when the decoupling assembly 500 is in a coupled configuration (described below), the expandable element 540 exerts a compressive force on the first engageable element 520 and the body 532 of the second engageable element 530 that prevents those components (and the decouplingassembly shaft 510) from rotating relative to one another about the decoupling-assembly rotational axis A500. The second end 540b of the expandable element 540 is received in the opening 534o defined through the flange 534 of the second engageable element 530. At least part of the decoupling-assembly shaft 510, the first engageable element 520, the second engageable element 530, and the expandable element 540 are housed within and circumscribed by the sleeve 550. The first end 540a of the expandable element is received in the opening 554o defined through the body 552 of the sleeve 550. The gear 580 is mounted to the second end 512b of the body 512 of the decoupling-assembly shaft 510 such that the gear 580 is fixed in rotation with the decoupling-assembly shaft 510. The spacer 570 separates the first engageable element 520 and the gear 580.

[0043] As best shown in Figure 5C, the decoupling assembly 500 is mounted to the frame 300f of the support 300 and operatively connected to the tensioning-assembly gearing. More specifically, the decoupling assembly 500 is mounted to the frame 300f via the fastener 560, which fixes the second engageable element 530 in rotation relative to the frame 300f such that the second engageable element 530 — and the second end 540b of the expandable element 540 received in the opening 534o of the flange 534 of the second engageable element 530 — cannot rotate relative to the frame 300f about the decoupling-assembly rotational axis A500. The gear 580 operably connects the body 512 of the decoupling-assembly shaft 510 to rollback ring gear 430 of the tensioning-assembly gearing. Specifically, the teeth on the gear 580 mesh with the teeth of the rollback intermediate gear 431, which in turn mesh with the external teeth 430ot of the rollback ring gear 430. In other embodiments, there is no rollback intermediate gear, and the teeth of the gear of the decoupling assembly mesh directly with the external teeth of the rollback ring gear.

[0044] The decoupling assembly 500 has a coupled configuration and a release configuration. Figure 5C shows the decoupling assembly 500 in the coupled configuration. When the decoupling assembly 500 is in the coupled configuration, the expandable element 540 exerts a compressive force on the first engageable element 520 and the body 532 of the second engageable element 530 that prevents them from rotating relative to one another about the decoupling-assembly rotational axis A500. Since the body 532 of the second engageable element 530 is fixed in rotation relative to the frame 300f of the support 300 and the decoupling-assembly shaft 510 is fixed in rotation with the first engageable element 520, the decoupling-assembly shaft 510 — and thus the gear 580 — is fixed in rotation relative to the frame 300f. Since the gear 580 meshes with the rollback intermediate gear 431, when in the coupled configuration the decoupling assembly 500 prevents the rollback intermediate gear 431 from rotating about the rocker axis A400r, which in turn prevents the rollback ring gear 430 from rotating about the tensioning-wheel axis A ow.

[0045] The decoupling assembly 500 is switchable (such as by the actuating assembly 600 as described below) from the coupled configuration to the release configuration to enable the first engageable element 520 and the decoupling-assembly shaft 510 to rotate relative to the second engageable element 530 about the decoupling-assembly rotational axis A500. As explained above, the second engageable element 530 and the second end 540b of the expandable element 540 (that is received in the opening 534o of the flange 534 of the second engageable element 530) are fixed in rotation relative to frame 300f. To switch the decoupling assembly 500 from the coupled configuration to the release configuration, the sleeve 550 is rotated about the decoupling-assembly rotational axis A500 from a coupled position to a release position in a release direction R550 relative to the frame 300f, the second end 540b of the expandable element 540, and the second engageable element 530. Since the first end 540a of the expandable element 540 is received in the opening 554o defined in the body 552 of the sleeve 550, the first end 540a rotates with the sleeve 550. As this occurs, the inner diameter of the expandable element 540 near its first end 540a begins expanding, and eventually expands enough (thereby reducing the compression force or eliminating it altogether) to enable the first engageable element 520 and the decoupling-assembly shaft 510 to rotate about the decoupling-assembly rotational axis Asoo relative to the second engageable element 530 (and the expandable element 540). When the sleeve 550 is released, the first end 540a of the expandable element 540 biases the sleeve 550 to rotate in a coupling direction C550 opposite the release direction R550 until the sleeve 550 reaches the coupled position (meaning the decoupling assembly 500 is back in its coupled configuration).

[0046] The actuating assembly 600, which is best shown in Figures 6A and 6B, is operably connected to the decoupling assembly 500 to switch it between the coupled and release configurations and is actuatable to initiate the opening process described below. The actuating assembly 600 includes an actuating-assembly body 610 and a decoupling-assembly actuator 620. The actuating-assembly body 610 includes a trigger 612, spaced-apart first and second mounting ears 614a and 614b extending from the trigger 612, a cam-engaging-assembly actuator 616 extending from the second mounting ear 614b, and an actuating rod 618 extending between the mounting ears 614a and 614b. Each mounting ear 614a and 614b defines a vertically extending slot therethrough. The decoupling-assembly actuator 620 includes an actuated arm 622, a gear arm 624 connected to the actuated arm 622, and a gear 626 at a free end of the gear arm 624.

[0047] The first and second mounting ears 614a and 614b of the actuating-assembly body 610 are pivotably mounted to frame 300f via pivot pins (not labeled). The decoupling assembly actuator 620 is pivotably mounted to an actuator mounting pin 690 that extends through the slots defined through the first and second mounting ears 614a and 614b of the actuating-assembly body 610 and that is secured (such as via retaining rings) to the frame 300f. The actuated arm 622 of the decoupling assembly actuator 620 is positioned above the actuating rod 618.

[0048] The actuating-assembly body 610 is pivotable relative to the frame 300f about an actuating-assembly-body axis Aeio between a home position (Figures 8A, 8F, and 8G) and an actuated position (Figures 8B-8E). A biasing element (not shown), such as a compression or torsion spring, biases the actuating-assembly body 610 to the home position. When the actuating-assembly body 610 is in the home position, the actuator mounting pin 690 is positioned at the top of the slots defined through the first and second mounting ears 614a and 614b of the actuating-assembly body 610. Conversely, when the actuating-assembly body 610 is in the actuated position, the actuator mounting pin 690 is positioned at the bottom of the slots. The actuator mounting pin 690 and the slots therefore define the range of (pivoting) movement of the actuating-assembly body 610.

[0049] The decoupling-assembly actuator 620 is pivotable relative to the frame 300f about an actuator axis A620 between a home position (Figure 8A) and an actuated position (Figures 8B-8G). A biasing element 620b, which is a torsion spring in this example embodiment but may be any suitable biasing element, biases the decoupling-assembly actuator 620 to its home position. The actuating-assembly body 610 is operably connected to the decouplingassembly actuator 620 to move the decoupling-assembly actuator 620 from its home position to its actuated position. Specifically, as the actuating-assembly body 610 moves from its home position toward its actuated position, the actuating rod 618 engages the actuated arm 622 of the decoupling-assembly actuator 620 and forces it to pivot about the actuator axis A620 until it (and the actuating-assembly body 610) reaches its actuated position.

[0050] The decoupling-assembly actuator 620 is positioned, oriented, and otherwise configured to control which configuration the decoupling assembly 500 is in. Specifically, when the decoupling-assembly actuator 620 is in its home position, as shown in Figure 8A, the decoupling assembly 500 is in its coupled configuration. The teeth of the gear 626 are unmeshed from the teeth 554 of the sleeve 550, and the sleeve 550 is in its coupled position. When the decoupling assembly actuator 620 moves from its home position to its actuated position, as shown in Figure 8B, the gear 626 meshes with the teeth 554 of the sleeve 550 and rotates the sleeve 550 in the release direction R550 until the sleeve 550 reaches its release position and the decoupling assembly 500 is in its release configuration. When the decoupling-assembly actuator 620 moves from its actuated position back to its home position, the gear 626 moves to enable the sleeve 550 to rotate in the coupling direction C550 back to its coupled position such that the decoupling assembly 500 is in its coupled configuration. In this embodiment, the gear 626 unmeshes from the teeth 554 of the sleeve 550 near the end of its movement.

[0051] The cam-engaging assembly 700, which is best shown in Figures 7A-7D, is movable by the actuating assembly 600 into a position to be engaged by one of the cams 424, 426, and 428 of the rocker mover 420 of the tensioning assembly 400 to raise the tensioning assembly 400 from its home position to its strap-insertion position. The cam-engaging assembly 700 includes a cam engager 710, an actuating-assembly engager 720, and a biasing element 730. The cam engager 710 includes a cam-engager body 712 and a cam-engaging finger 714 extending transversely from the cam-engager body 712. The actuating-assembly engager 720 includes an actuating-assembly-engager body 722, an actuator-engaging finger 724 extending from the actuating-assembly-engager body 722, and a stop 726 extending from the actuating- assembly-engager body 722. The cam engager 710 is pivotably connected to the actuatingassembly engager 720 such that the cam engager 710 and the actuating-assembly engager 720 can pivot relative to one another about a cam-engager rotational axis A710. Figure 7C shows the cam-engaging assembly 700 when the cam engager 710 is in a home position relative to the actuating-assembly engager 720 such that the cam-engaging finger 714 of the cam actuator 710 is spaced-apart from the actuating-assembly-engager body 722 of the actuating-assembly engager 720. Figure 7D shows the cam-engaging assembly 700 when the cam engager 710 is in an actuated position relative to the actuating-assembly engager 720 such that the cam-engaging finger 714 is closer to (and in certain embodiments engaging) the actuating-assembly-engager body 722. The biasing element 730, which is a compression spring in this example embodiment but may be any other suitable biasing element, biases the cam engager 710 to its home position, and the cam engager 710 engages the stop 726, which prevents further rotation.

[0052] As best shown in Figures 9A-10D, the cam-engaging assembly 700 — and particularly the cam engager 710 and the actuating-assembly engager 720 — are pivotably mounted to the tensioning-assembly mounting shaft 395 and configured to pivot about a cam- engaging-assembly axis A720 (which is coaxial with the rocker axis A4oor) relative to the support 300 between a home configuration (Figures 9A, 9G, and 10A); a cam-engaging configuration (Figures 9B and 10D); and a stop configuration (Figures 9C-9G). When the cam-engaging assembly 700 is in the home configuration, the cam engager 710 is in its home position relative to the actuating-assembly engager 720, the actuator-engaging finger 724 is below the cam- engaging-assembly actuator 616, and the cam-engaging finger 714 is in a home position removed from the rotational path of the first, second, and third cams 424, 426, and 428 of the rocker mover 420. A biasing element, which as an extension spring or any other suitable spring, biases the cam-engaging assembly 700 to the home configuration. When the cam-engaging assembly 700 is in the cam-engaging configuration, the cam engager 710 is in its home position relative to the actuating-assembly engager 720 and the cam-engaging finger 714 is in a cam-engaging position. When the cam-engaging finger 714 is in the cam-engaging position, the cam-engaging finger 714 extends across the rotational path of the first, second, and third cams 424, 426, and 428 of the rocker mover 420. When the cam-engaging assembly 700 is in the stop configuration, the cam engager 710 is in its home position relative to the actuating-assembly engager 720 and the cam-engaging finger 714 is in a stop position and engages a stop 390 mounted to the frame 300f. Accordingly, when the cam-engaging finger 714 is in the cam-engaging position, the camengaging finger 714 extends across the rotational path of the first, second, and third cams 424, 426, and 428 of the rocker mover 420 such that rotation of the rocker mover 420 results in one of the cams engaging and forcing the cam-engaging finger 714 toward the stop position.

[0053] The sealing assembly 900, which is best shown in Figure 3A, is configured to attach overlapping layers of the strap to one another to form a tensioned strap loop around the load during the sealing process via friction welding. The sealing assembly 900 includes a weld arm 910, a weld shoe 912, a cutter 914, a linkage 916, and an eccentric shaft (not shown). The weld shoe 912 is slidably mounted to the weld arm 910 such that the weld shoe 912 can oscillate relative to the weld arm 910. The cutter 914 is mounted to the weld arm 910. The weld arm 910 is pivotably mounted to the support 300 and is pivotable relative to the support 300 and the weld plate 314 about a weld-arm axis A910 between a home position (Figure 3A) in which the weld shoe 912 is spaced-apart from the weld plate 314 and a welding position (not shown) in which the weld shoe 912 is adjacent the weld plate 314 and positioned to weld the strap. The linkage 916 operably connects the transmission 1000 to the weld arm 910 such that the transmission 1000 can move the weld arm 910 from the release home position to the welding position (and vice-versa in certain embodiments). The eccentric is operably connected to the weld shoe 912 and configured to, when rotated, cause the weld shoe 912 to oscillate. A toothed belt 900b operably connects the transmission 1000 to the eccentric to rotate the eccentric.

[0054] The transmission 1000, which is best shown in Figures 3 A and 3B, is driven by the motor 1100, is operably connected to the tensioning assembly 400 and configured to cause the tension wheel 400w to rotate in the tensioning direction T to tension the strap and to cause the tensioning assembly 400 to pivot to its strap-insertion position, and is operably connected to the sealing assembly 900 and configured to cause the sealing assembly 900 to attach the overlapping layers of the strap to one another. The transmission 1000 includes transmission gearing including a drive gear 1012 (which is a bevel pinion gear in this example embodiment) and a variable offset coupling 800 including a driven gear (which is a bevel wheel gear in this example embodiment). The transmission gearing and the variable offset coupling 800 are mounted to the support 300 such that the drive gear 1012 meshes with the driven gear.

[0055] The transmission gearing 1010 includes suitable components (such as gears, bearing, and freewheels) that transmit rotational movement of the output shaft of the motor 1100 in a first drive direction to the drive gear 1012 to rotate the drive gear 1012 (but not to drive any components of the sealing assembly 900 in this example embodiment). The drive gear 1012 drives the driven gear to rotate in the tensioning direction T, and the other components of the variable offset coupling 800 transmit the rotational movement of the driven gear 1022 to the driven shaft 410 of the tensioning assembly 400 to rotate the driven shaft 410 in the tensioning direction T. The components of the transmission gearing 1010 transmit rotational movement of the output shaft of the motor 1100 in a second drive direction opposite the first drive direction to: (1) the linkage 916 of the sealing assembly 900 to move the weld arm 910 from its home position to its welding position; and (2) the toothed belt 990 to rotate the eccentric and cause the weld shoe 912 to oscillate (but not to drive the drive gear 1012 in this example embodiment).

[0056] This is merely one example transmission assembly, and the strapping device may include any suitable transmission assembly or assemblies operably connecting one or more motors to the tensioning and sealing assemblies to drive those assemblies.

[0057] The motor 1100, which is best shown in Figures 3 A and 3B, is operably connected to (via the transmission 1000) the tensioning assembly 400 and the sealing assembly 900 and is configured to drive those assemblies as explained herein. The motor 1100 includes the output shaft (not shown) referenced above. The motor 1100 is an electric motor in this example embodiment but may be any suitable motor.

[0058] The display assembly 1490, which is shown in Figures 1A-1C, includes a suitable display screen 1492 with a touch panel 1494. The display screen 1492 is configured to display information regarding the strapping device 50 (at least in this embodiment), and the touch screen 1494 is configured to receive operator inputs such as a desired strap tension and desired weld cooling time. A display controller (not shown) may control the display screen 1492 and the touch panel 1494 and, in these embodiments, is communicatively connected to the controller 1600 to send signals to the controller 1600 and to receive signals from the controller 1600. Other embodiments of the strapping device do not include a touch panel. Still other embodiments of the strapping device do not include a display assembly. Certain embodiments of the strapping device include a separate pushbutton panel instead of a touch panel beneath or integrated with the display screen.

[0059] The first and second pushbutton actuators 1410 and 1440 are operable to initiate the tensioning and/or sealing processes as described below. Other embodiments of the strapping device 50 do not have pushbutton actuators and instead incorporate their functionality into the display assembly 1490. For instance, in one of these embodiments two areas of the touch panel define virtual buttons that have the same functionality as mechanical pushbutton actuators.

[0060] The controller 1600, which is shown in Figure 1C, includes a processing device (or devices) communicatively connected to a memory device (or devices). For instance, the controller may be a programmable logic controller. The processing device may include any suitable processing device such as, but not limited to, a general-purpose processor, a specialpurpose processor, a digital-signal processor, one or more microprocessors, one or more microprocessors in association with a digital-signal processor core, one or more applicationspecific integrated circuits, one or more field-programmable gate array circuits, one or more integrated circuits, and/or a state machine. The memory device may include any suitable memory device such as, but not limited to, read-only memory, random-access memory, one or more digital registers, cache memory, one or more semiconductor memory devices, magnetic media such as integrated hard disks and/or removable memory, magneto-optical media, and/or optical media. The memory device stores instructions executable by the processing device to control operation of the strapping device 50. The controller 1600 is communicatively and operably connected to the motor 1100, the display assembly 1490, the pushbutton actuators 1410 and 1440, and the sensor(s) 1700 and configured to receive signals from and to control those components. The controller 1600 may also be communicatively connectable (such as via Wi-Fi, Bluetooth, near-field communication, or other suitable wireless communications protocol) to an external device, such as a computing device, to send information to and receive information from that external device.

[0061] The controller 1600 is configured to operate the strapping device in one of three operating modes to carry out the strapping process: (1) a manual operating mode; (2) a semi-automatic operating mode; and (3) an automatic operating mode. In the manual operating mode, the controller 1600 operates the motor 1100 to cause the tension wheel 400w to rotate responsive to the first pushbutton actuator 1410 being actuated and maintained in its actuated state. The controller 1600 operates the motor 1100 to cause the sealing assembly 900 to carry out the sealing process responsive to the second pushbutton actuator 1440 being actuated. In the semi-automatic operating mode, the controller 1600 operates the motor 1100 to cause the tension wheel 400w to rotate responsive to the first pushbutton actuator 1410 being actuated and maintained in its actuated state. Once the controller 1600 determines that the tension in the strap reaches the (preset) desired strap tension, the controller 1600 automatically operates the motor 1100 to cause the sealing assembly 900 to carry out the sealing process (without requiring additional input from the operator). In the automatic operating mode, the controller 1600 operates the motor 1100 to cause the tension wheel 400w to rotate responsive to the first pushbutton actuator 1410 being actuated. Once the controller 1600 determines that the tension in the strap reaches the (preset) desired strap tension, the controller 1600 automatically operates the motor 1100 to cause the sealing assembly 900 to carry out the sealing process (without requiring additional input from the operator).

[0062] The sensors 1700 include any suitable sensors, such as microswitches, optical sensors, ultrasonic sensors, magnetic position sensors, and the like, configured to detect the position of certain components of the strapping device 50 and to send appropriate signals to the controller 1600. In this example embodiment, as shown in Figure 12, the sensors 1700 include a first sensor 1710, a second sensor 1720, and a third sensor 1730, which are limit switches in this example embodiment but may be any other type of sensor in other embodiments.

[0063] In this example embodiment, the first sensor 1710 is positioned and otherwise configured to detect when the actuating-assembly body 610 is in its home position and, conversely, when the actuating assembly 600 has moved away from its home position. Specifically, the first sensor 1710 is positioned and otherwise configured to detect the cam- engaging-assembly actuator 616 when the actuating-assembly body 610 is in its home position, though the first sensor 1710 may be configured to detect any suitable element of the actuating assembly 600.

[0064] In this example embodiment, the second sensor 1720 is positioned and otherwise configured to detect when the actuating-assembly body 610 is in its actuated position and, conversely, when the actuating-assembly body 610 has moved away from its actuated position. Specifically, the second sensor 1720 is positioned and otherwise configured to detect the trigger 612 when the actuating-assembly body 610 is in its actuated position, though the second sensor 1720 may be configured to detect any suitable element of the actuating assembly 600. In other embodiments, the second sensor is positioned and otherwise configured to detect when the actuating-assembly body has moved away from its home position. In further embodiments, the second sensor is positioned and otherwise configured to detect when the actuating-assembly body has reached a certain position between its home and actuated positions.

[0065] In this example embodiment, the third sensor 1730 is positioned and otherwise configured to detect when the tensioning assembly 400 is in its strap-insertion position and, conversely, when the tensioning assembly 400 has moved away from its strap-insertion position. In this example embodiment, the third sensor 1730 is mounted to the support 300 and positioned and otherwise configured to detect the rocker 400r when the tensioning assembly 400 is in its strap-tensioning position, though the third sensor 1730 may be configured to detect any suitable element of the tensioning assembly 400. In other words, in this example embodiment, the third sensor 1730 is positioned and otherwise configured to detect when the tensioning assembly 400 is in its strap-insertion position by directly detecting a component of the tensioning assembly 400. In other embodiments, the third sensor is positioned and otherwise configured to detect component of the strapping device when the tensioning assembly is in the strap-insertion position. In other words, in these embodiments, the third sensor is configured to indirectly detect when the tensioning assembly is in the strap-insertion position by detecting a component other than a component of the tensioning assembly when the tensioning assembly is in the strapinsertion position. For instance, in one such embodiment, the third sensor is mounted to the rocker of the tensioning assembly and configured to detect the cam-engaging finger of the camengaging assembly when both (a) the cam-engaging finger is in the stop position (i.e., engaging the stop mounted to the frame of the support) and (b) the rocker (and therefore the tensioning assembly) is in the strap-insertion position. In another such embodiment, the third sensor is mounted to the rocker of the tensioning assembly and configured to detect the support when the rocker (and therefore the tensioning assembly) is in the strap-insertion position.

[0066] The power supply 1500 is electrically connected to (via suitable wiring and other components) and configured to power several components of the strapping device 50, including the motor 1100, the display assembly 1490, the controller 1600, and the sensor(s) 1700. The power supply 1500 includes a rechargeable battery (such as a lithium-ion or nickel cadmium battery) in this example embodiment, though it may be any other suitable electric power supply in other embodiments. The power supply 1500 is sized, shaped, and otherwise configured to be received in the receptacle defined by the rear housing section 120 of the housing 100. The strapping device 50 includes one or more power-supply-securing devices (not shown) to releasably lock the power supply 1500 in place upon receipt in the receptacle. Actuation of a release device of the strapping device 50 or the power supply 1500 unlocks the power supply 1500 from the housing 100 and enables an operator to remove the power supply 1500 from the receptacle.

[0067] Figure 13 is a flowchart of an example opening process 2000 of the present disclosure that, when carried out by the strapping device 50, results in the tensioning assembly 400 moving to the strap-insertion position unless a first shut-off condition is met that terminates the opening process. The opening process 2000 begins by determining that an opening condition has been met, as block 2010 indicates. The opening process 2000 continues by activating a motor to begin rotating a rocker mover, as block 2020 indicates. The opening process 2000 continues by simultaneously monitoring whether a first shut-off condition is met, as diamond 2030 indicates, and whether a tool-opened condition is met, as diamond 2040 indicates. Once either the first shut-off condition is met or the tool-opened condition is met, the opening process 2000 concludes by stopping the motor to stop rotating the rocker mover, as block 2050 indicates.

[0068] In this example embodiment, the opening condition is met when the actuating-assembly body 610 reaches its actuated position. The controller 1600 determines whether the opening condition is met based on sensor feedback, and in particular based on the second sensor 1720 detecting the trigger 612 when the actuating-assembly body 610 reaches its actuated position. In this example embodiment, the first shut-off condition is met if the tool- opened condition has not been met within a designated period — such as a time period or a quantity of rotations of the output shaft of the motor 1100 — after the opening condition is met or after the motor is activated. In this example embodiment, the tool-opened condition is met when the rocker reaches the strap-insertion position. The controller 1600 determines whether the first shut-off condition is met and whether the tool-opened condition is met based on sensor feedback, and in particular based on feedback from the third sensor 1730 that is configured to detect when the tensioning assembly 400 (and the rocker 400r thereof) has reached the strap-insertion position.

[0069] In one example implementation of the opening process 2000 by the strapping device 50, the controller 1600 determines that the opening condition has been met responsive to the second sensor 1720 detecting the trigger 612 after the actuating-assembly body 610 has moved to the actuated position. In response to receiving a corresponding signal from the second sensor 1720, the controller 1600 activates the motor 1100 to begin rotating the output shaft in the first drive direction, which as described below causes the rocker mover 420 to rotate about the tension-wheel rotational axis A4oo in the tensioning direction T. The controller 1600 then simultaneously monitors whether the first shut-off condition is met and whether the tool-opened condition is met. The controller 1600 does so based on feedback from the third sensor 1730. In this example, the controller 1600 receives a signal from the third sensor 1730 indicating detection of the rocker 400r at the strap-insertion position before the designated period expires. Accordingly, the controller 1600 determines that the tensioning assembly 400 is in the strapinsertion position — and therefore that the tool-opened condition has been met — and controls the motor 1100 to stop rotating the output shaft, terminating the opening process.

[0070] In another example implementation of the opening process 2000 by the strapping device 50, the controller 1600 determines that the opening condition has been met responsive to the second sensor 1720 detecting the trigger 612 after the actuating-assembly body 610 has moved to the actuated position. In response to receiving a corresponding signal from the second sensor 1720, the controller 1600 activates the motor 1100 to begin rotating the output shaft in the first drive direction, which as described below causes the rocker mover 420 to rotate about the tension-wheel rotational axis A400W in the tensioning direction T. The controller 1600 then simultaneously monitors whether the first shut-off condition is met and whether the tool- opened condition is met . In this example, the controller 1600 does not receive any signal from the third sensor 1730 before the designated period expires. Accordingly, the controller 1600 determines that the tensioning assembly 400 has not reached the strap-insertion position — and therefore that the tool-opened condition has not been met — and controls the motor 1100 to stop rotating the output shaft. In certain embodiments, the controller 1600 also causes an output — such as a message on the display 1490 or an audible tone — indicative of an error message. [0071] In other embodiments, the opening condition is met when the actuatingassembly body has moved away from its home position (as detected by the second sensor). In further embodiments, the opening condition is met when the actuating-assembly body has reached a certain position between its home and actuated positions (as detected by the second sensor). In other embodiments, the tool-opened condition is met when both (a) the cam-engaging finger is in the stop position (i.e., engaging the stop mounted to the frame of the support) and (b) the rocker (and therefore the tensioning assembly) is in the strap-insertion position.

[0072] The inclusion of the first shut-off condition in the opening process addresses a scenario in which the actuating assembly is moved to the actuated position but is either released before a cam of the rocker mover engages the cam-engaging finger of the cam engager or due to a mechanical failure fails to move the cam-engaging finger across the rotational path of the cams of the cam engager. Without the inclusion of the first shut-off condition to stop the motor in this scenario, the motor would run indefinitely in response to either of these scenarios.

[0073] Figure 14 is a flowchart of an example tensioning process 3000 of the present disclosure that, when carried out by the strapping device 50, results in the tensioning assembly 400 tensioning the strap around the load unless a second shut-off condition is met that terminates the tensioning process. The tensioning process 3000 begins by determining that a tensioning condition has been met, as block 3010 indicates. The tensioning process 3000 continues by activating a motor to begin rotating a tension wheel and a rocker mover, as block 3020 indicates. The tensioning process 3000 continues by simultaneously monitoring whether a second shut-off condition is met, as diamond 3030 indicates, and whether the motor is still active, as diamond 3040 indicates. The tensioning process 3000 concludes once the motor is shut off or once the second shut-off condition is met, in which case the motor is stopped, as block 3050 indicates.

[0074] In this example embodiment, the tensioning condition is met when the first pushbutton actuator 1410 is actuated. The controller 1600 determines whether the tensioning condition is met based on sensor feedback, and in particular based on a sensor configured to detect actuation of the first pushbutton actuator 1410. In this example embodiment, the second shut-off condition is met if the actuating-assembly body 610 moves away from its home position while the motor 1100 is operating after the tensioning condition is met. The controller 1600 determines whether the second shut-off condition is met based on sensor feedback, and in particular based on feedback from the first sensor 1710 that is configured to detect when the actuating-assembly body 610 has moved away from the home position.

[0075] In one example implementation of the tensioning process 3000 by the strapping device 50, the controller 1600 determines that the tensioning condition has been met responsive to the first pushbutton actuator being actuated. In response to receiving a corresponding signal from the appropriate sensor detecting the actuation, the controller 1600 activates the motor 1100 to begin rotating the output shaft in the first drive direction, which as described below causes the tension wheel 400w and the rocker mover 420 to rotate about the tension-wheel rotational axis A4oo« in the tensioning direction T to begin tensioning the strap. The controller 1600 then simultaneously monitors whether the second shut-off condition is met (based on feedback from the first sensor 1710) and whether the motor is still active. In this example, the controller 1600 determines that the motor has stopped, terminating the tensioning process.

[0076] In another example implementation of the tensioning process 3000 by the strapping device 50, the controller 1600 determines that the tensioning condition has been met responsive to the first pushbutton actuator being actuated. In response to receiving a corresponding signal from the appropriate sensor detecting the actuation, the controller 1600 activates the motor 1100 to begin rotating the output shaft in the first drive direction, which as described below causes the tension wheel 400w and the rocker mover 420 to rotate about the tension-wheel rotational axis AMOW in the tensioning direction T to begin tensioning the strap. The controller 1600 then simultaneously monitors whether the second shut-off condition is met (based on feedback from the first sensor 1710) and whether the motor is still active. In this example, the controller 1600 receives a signal from the first sensor 1710 indicating that the actuating-assembly body 610 has moved away from its home position. Accordingly, the controller 1600 determines that the second shut-off condition has been met and controls the motor 1100 to stop rotating the output shaft, terminating the tensioning process.

[0077] The inclusion of the second shut-off condition in the tensioning process addresses a scenario in which the actuating assembly is moved away from the home position while strap is being tensioned around the load. Without the inclusion of the second shut-off condition to stop the motor in this scenario, the actuating assembly would move the camengaging finger across the rotational path of the cams of the rocker mover and inadvertently cause the tensioning assembly to move to the strap-insertion position during tensioning, thus stopping the tensioning process and releasing the tension in the strap.

[0078] One example use of the strapping device 50 to form a tensioned strap loop around a load is described below. Initially, the tensioning assembly 400 is in its home position, the actuating-assembly body 610 is in its home position (meaning that the decoupling assembly 500 is in its coupled configuration), the cam-engaging assembly 700 is in its home configuration, and the weld arm 910 is in its home position, as shown in Figures 8A and 9A. The strapping device 50 is in the automatic mode for the purposes of this example.

[0079] The operator pulls the strap leading-end first from a strap supply (not shown), wraps the strap around the load, and positions the leading end of the strap S below another layer of the strap to form upper and lower layers of strap. The operator then pulls the trigger 612 and in doing so moves the actuating-assembly body 610 from the home position to the actuated position, as shown in Figures 8B and 9B. As this occurs, and as described above, the decouplingassembly actuator 620 switches the decoupling assembly 500 from the coupled configuration to the release configuration. Additionally, the pivoting of the actuating-assembly body 610 causes the cam-engaging-assembly actuator 616 to engage the actuator-engaging finger 724 and force the cam-engaging assembly 700 to move to its cam-engaging configuration. Once the second sensor 1720 detects that the actuating-assembly body 610 has reached the actuated position, the controller 1600 controls the motor 1100 to rotate the output shaft in the first drive direction to begin carrying out the opening process 2000.

[0080] As explained above, the transmission 1000 transmits this rotational movement of the output shaft to the drive shaft 410 of the tensioning assembly 400 and rotates it in the tensioning direction T. This causes the first sun gear 410b to rotate about the tensionwheel rotational axis A in the tensioning direction T. The first sun gear 410b drives the first set of planet gears 414a-414c. Since the first set of planet gears 414a-414c are fixed in rotation about the tensioning-wheel axis A ow, they drive the rocker mover 420 to rotate about the tension-wheel rotational axis A400w in the tensioning direction T. Eventually, the leading end of one of the cams 424, 426, and 428 — here the leading end 4241 e of the first cam 424 — engages the cam-engaging finger 714 — which extends across the rotational path of the cams — and forces the cam-engaging finger 714 to pivot until it engages the stop 390, thereby moving the camengaging assembly 700 to its stop configuration, as shown in Figures 8C and 9C. Since the stop 390 prevents further pivoting of the cam-engaging finger 714 and the cam 424 bears against the cam-engaging finger 714, continued rotation of the rocker mover 420 forces the rocker 400r and the entire tensioning assembly 400 to pivot upward about the rocker axis A r toward its strapinsertion position.

[0081] The first sun gear 410b also drives the second set of planet gears 434a-434d. Since the decoupling assembly 500 is in its release configuration, the rollback ring gear 430 is rotatable about the tension-wheel rotational axis A400W, and rotation of the second set of planet gears 434a-434d causes the rollback ring gear 430 to rotate about the tension-wheel rotational axis A4oow in the tensioning direction T rather than causing the second carrier 430 — and the tension wheel 400w — to rotate (though there may be a small amount of rotation due to drag torque). Once the controller 1600 determines that the tensioning assembly 400 has reached its strap-insertion position (such as based on feedback from one of the sensors 1700), as shown in Figures 8D and 9D, the controller 1600 controls the motor 1100 to stop rotating the output shaft. Generally, the apex 424s’ of the finger-engaging surface 424s of the cam 424 engages the camengaging finger 714 when the tensioning assembly 400 is in its strap-insertion position. In other words, the bearing point of the cam 424 against the cam-engaging finger 714 is the apex 424s’. The tensioning-assembly freewheel 412 prevents the driven shaft 410 from reversing, ensuring the tensioning assembly 400 remains in the strap-insertion position. Accordingly, the tensioningassembly gearing operatively connects the motor 1100 and the transmission 1000 to the tensioning assembly 400 to move the tensioning assembly 400 from its home position to its strap-insertion position.

[0082] With the tensioning assembly 400 in its strap-insertion position and while continuing to pull the trigger 612 to hold the actuating-assembly body 610 in the actuated position, the operator introduces the overlapping upper and lower layers of the strap between the tension wheel 400w and the tension plate 312 and between the weld shoe 912 and the weld plate 314, as shown in Figures 8E and 9E. The operator then releases the trigger 612, enabling the appropriate biasing elements to force the actuating-assembly body 610 to return to its home position as shown in Figures 8F and 9F. A catch (not shown) engages the projection 622a of the actuated arm 622 of the decoupling assembly actuator 620 and holds it in place, holding the decoupling assembly 500 in its release configuration. [0083] Once the first sensor 1710 detects that the actuating-assembly body 610 has reached the home position, the controller 1600 controls the motor 1100 to rotate the output shaft in the first drive direction. As explained above, this causes the rocker mover 420 to rotate about the tension-wheel rotational axis A ow in the tensioning direction T. As the rocker mover 420 rotates, the bearing point of the cam 424 against the cam-engaging finger 714 (i.e., the point of engagement between the finger-engaging surface 424s of the cam 424 that engages the camengaging finger 714) shifts from its apex 424s’ toward the trailing end 424te of the cam 424. The curved shape and the orientation of the finger-engaging surface 424se causes the tensioning assembly 400 to gradually lower from its strap-insertion position toward its tensioning position while the cam engages the cam-engaging finger 714, as shown in Figures 8F and 9F. Continued rotation of the rocker mover 420 eventually causes the cam to disengage the cam-engaging finger 714, at which point suitable biasing elements force the tensioning assembly 400 to complete the movement to its tensioning position and to move the cam-engaging assembly 700 back to its home position, as shown in Figures 8G and 9G. Once the controller 1600 determines that the tensioning assembly 400 has reached its tensioning position (such as based on feedback from one of the sensors 1700), the controller 1600 controls the motor 1100 to stop rotating the output shaft.

[0084] The operator then actuates the first pushbutton actuator 1410, which (via a pivoting lever) causes the catch to disengage the projection 622a of the actuated arm 622 of the decoupling assembly 620. As described above, this enables the decoupling assembly 500 to — via the biasing forces imparted by the expandable element 540 and the biasing element 620b — switch from its release configuration to its coupled configuration to enable the motor 1100 to operate to tension the strap S. Once one of the sensors 1700 detects the actuation of the first pushbutton actuator 1410, the controller 1600 initiates the strapping process by first carrying out the tensioning process 3000. The controller 1600 controls the motor 1100 to rotate the output shaft in the first drive direction. As explained above, the transmission 1000 transmits this rotational movement of the output shaft to the drive shaft 410 of the tensioning assembly 400 and rotates it in the tensioning direction T. This causes the first sun gear 410b to rotate about the tension- wheel rotational axis A400W in the tensioning direction T. The first sun gear 410b drives the first set of planet gears 414a-414c. Since the first set of planet gears 414a-414c are fixed in rotation about the tensioning-wheel axis A ow, they drive the rocker mover 420 to rotate about the tension-wheel rotational axis A400W in the tensioning direction T. Since the cam-engaging assembly 700 is in its home configuration, the cam-engaging finger 714 is not in the rotational path of the cams 424, 426, and 428 of the rocker mover 420 and the tensioning assembly 400 does not pivot from its tensioning position.

[0085] The first sun gear 410b also drives the second set of planet gears 434a-434d. Since the decoupling assembly 500 is in its coupled configuration, it prevents the rollback ring gear 430 from rotating about the tension-wheel rotational axis A400W, and rotation of the second set of planet gears 434a-434d causes the carrier 432 — including the second sun gear 432b — to rotate about the tension-wheel rotational axis A400W in the tensioning direction T. The second sun gear 432b drives the third set of planet gears 436a-436c, which causes the tension wheel 400w to rotate about the tension-wheel rotational axis A400W in the tensioning direction T. Accordingly, the tensioning-assembly gearing operatively connects the motor 1100 and the transmission 1000 to the tension wheel 400w to rotate the tension wheel 400w about the tension-wheel rotational axis A400W in the tensioning direction T.

[0086] As the tension wheel 400w rotates in the tensioning direction T, it pulls the upper layer of the strap S over the lower layer of the strap S, thereby tensioning the strap S around the load. Throughout the tensioning process, the controller 1600 monitors the current drawn by the motor 1100. When this current reaches a preset value that is correlated with the (preset) desired strap tension for this strapping process, as explained above, the controller 1600 stops the motor 1100, thereby terminating the tensioning process. At this point, the strap exerts a torque on the tension wheel 400w in the rollback direction TREV. The tension wheel 400w transmits this torque to the third set of planetary gears 436a-436c, which transmit this torque to the second sun gear 432b of the carrier 432. The second set of planetary gears 434a-434d transmit this torque to the first sun gear 410b of the driven shaft 410 and to the rollback ring gear 430. The tensioning-assembly freewheel 412 prevents the driven shaft 410 from rotating in the rollback direction TREV. The decoupling assembly 500 is in its coupled configuration and prevents the rollback ring gear 430 from rotating in the rollback direction TREV. Accordingly, the torque the strap exerts on the tension wheel 400w is absorbed by components of the tensioning assembly 400 and the decoupling assembly 500, enabling the tension wheel 400w to hold tension in the strap without rotating in the rollback direction TREV. [0087] After completion of the tensioning process, the controller 1600 automatically starts the sealing process by controlling the motor 1100 to begin rotating the output shaft in the second drive direction. This causes the transmission 1000 to drive the toothed belt 900b to begin rotating the eccentric and oscillating the weld shoe 912 and pivot the weld arm 910 to its welding position. As the weld arm 910 reaches the welding position, the weld shoe 912 forces the overlapping upper and lower layers of strap against the weld plate 314 while the cutter 914 cuts the upper strap layer from the strap supply. The oscillating movement of the weld shoe 912 locally melts the portions of the upper and lower strap layers together. After a preset period of time or a preset quantity of rotations of the motor output shaft, the controller 1600 controls the motor 1100 to stop rotating the output shaft, completing the sealing process.

[0088] After the sealing process is complete, the operator again pulls the trigger 612, and in doing so moves the actuating-assembly body 610 from the home position to the actuated position. As this occurs, and as described above, the decoupling assembly actuator 620 switches the decoupling assembly 500 from the coupled configuration to the release configuration. After the sealing process is complete, the strap continues to exert the torque on the tension wheel 400w that acts in the rollback direction TREV. Switching the decoupling assembly 500 from the coupled configuration to the release configuration enables the tension wheel 400w to rotate in the rollback direction TREV to release that torque in a controlled manner.

[0089] Specifically, upon completion of the strapping process, the decoupling assembly 500 continues to prevent the rollback ring gear 430 of the tensioning-assembly gearing from rotating in the rollback direction TREV, which as explained above prevents the tension wheel 400w from rotating in the rollback direction TREV after tensioning so the tension wheel 400w can hold the tension in the strap. As the operator moves the actuating-assembly body 610 to its actuated position, the decoupling assembly actuator 620 begins rotating the sleeve 550 of the decoupling assembly 500 to its release position, and the inner diameter of the expandable element 540 of the decoupling assembly 500 begins expanding. Eventually, the torque the rollback ring gear 430 exerts on the decoupling-assembly shaft 510 of the decoupling assembly 500 (via the rollback intermediary gear 431 and the gear 580 of the of the decoupling assembly 500) exceeds the compression force the expandable element 540 exerts on the first engageable element 520. When this occurs, the rollback ring gear 430 begins rotating in the rollback direction TREV about the tension-wheel rotational axis A400W, enabling the second set of planetary gears 434a-434d and the carrier 432 to rotate in the rollback direction TREV about the tensionwheel rotational axis A400W. This causes the tension wheel 400w to rotate in the rollback direction TREV about the tension-wheel rotational axis A400W to release the torque exerted by the tensioned strap.

[0090] The second sensor 1720 detects that the actuating-assembly body 610 has reached the actuated position, the controller 1600 controls the motor 1100 to rotate the output shaft in the first drive direction to raise the tensioning assembly 400 to its strap-insertion position, as explained above. The operator then removes the strapping device 50 from the tensioned strap loop.

[0091] Figures 10A-10D show a scenario in which a cam of the rocker mover 420 is in the path of the cam-engaging finger 714 of the cam-engaging assembly 700 and preventing the cam-engaging finger 714 from moving to its cam-engaging configuration when the actuatingassembly body 610 moves to its actuated position. Initially, as shown in Figure 10A, the actuating-assembly body 610 is in its home position and cam-engaging assembly 700 is in its home configuration. The operator begins pulling the trigger 612 and in doing so moving the actuating-assembly body 610 from the home position toward the actuated position, as shown in Figure 10B. As this occurs, as also shown in Figure 10B, the cam-engaging-assembly actuator 616 engages the actuator-engaging finger 724 and begins forcing the cam-engaging assembly 700 to move toward its cam-engaging configuration. Eventually, as also shown in Figure 10B, the cam-engaging finger 714 contacts the finger-engaging surface 424s of one of the cams (here, the cam 424) of the rocker mover 420, which prevents the cam-engaging finger 714 from rotating any further. As the operator continues pulling the trigger 612 and in doing so continues moving the actuating-assembly body 610 from the home position toward the actuated position, the cam-engaging-assembly actuator 616b begins forcing the actuating-assembly engager 720 to pivot relative to the cam engager 710 against the biasing force of the biasing element 730, thereby beginning to move the cam engager 710 relative to the actuating-assembly engager from its home position to its actuated position. This continues until the actuating-assembly body 610 and the cam engager 710 reach their respective actuated positions, as shown in Figure 10C. Once one of the sensors 1700 detects that the actuating-assembly body 610 has reached its actuated position, the controller 1600 controls the motor 1100 to rotate the output shaft in the first drive direction. As described above, this causes the rocker mover 420 and the cams thereon to begin rotating. Eventually, the cam 424 rotates out of engagement with the cam-engaging finger 714, and the appropriate biasing elements force the cam engager 710 back to its home position and the cam-engaging assembly 700 to its cam-engaging configuration in which the cam-engaging finger 714 extends across the rotational path of the cams, as shown in Figure 10D. Continued rotation of the rocker mover 420 causes the leading end 4261e of the next cam 426 to engage the camengaging finger 714 and, eventually, move the tensioning assembly 400 to the strap-insertion position, as explained above. Accordingly, the ability of the cam engager 710 to pivot relative to the actuating-assembly engager 720 enables the operator to move the actuating-assembly body 610 from its home position to its actuated position without interference even if a cam of the rocker mover 420 is in the path of the cam-engaging finger 714.

[0092] The ability of the cam engager 710 to pivot relative to the actuating-assembly engager 720 enables the operator to move the actuating-assembly body 610 from its home position to its actuated position without interference even if a cam of the rocker mover 420 is in the path of the cam-engaging finger 714. Figures 11A-11C show such a scenario in which the cam-engaging finger 714 of the cam engager 710 of the cam-engaging assembly 700 is in the rotational path of a cam of the rocker mover 420 but does not extend across the rotational path. Initially, as shown in Figure HA, the rocker mover 420 is rotating, and the actuating-assembly body 610 is moved from its home position toward its actuated position, thereby causing the camengaging assembly 700 to move from its home configuration toward its cam-engaging configuration. Before the cam-engaging finger 714 reaches its cam-engaging position, the leading end 4241e of the first cam 424 of the rocker moves 420 engages the tip of the camengaging finger 714. Since at this point the cam-engaging finger 714 does not extend across the rotational path of the first cam 424, continued rotation of the rocker mover 420 results in the first cam 424 forcing the cam-engager 710 to pivot relative to the actuating-assembly engager 420 from its home position toward its actuated position, as shown in Figures 1 IB and 11C, rather than toward its stop position. Accordingly, if the cam engager 710 is inadvertently moved into the rotational path of the cams of the rocker mover 420 while the rocker mover 2420 is rotating and is contacted by one of the cams before extending across the rotational path, the configuration of the cam-engaging assembly 700 enables the rocker mover 420 to move the cam engager 710 out of the rotational path without measurably affecting the rotation of the rocker mover 420. [0093] Although the sealing assembly of the above-described example embodiments of the strapping device is configured to form a friction-welded strap joint, the sealing assembly may comprise other sealing mechanisms (such as notching jaw assembly, a crimping jaw assembly, a sealless joint assembly, an ultrasonic welding assembly, or a hot-knife assembly) in other embodiments configured to seal any suitable type of strap (such as metal, plastic, or paper strap).

[0094] The above-described example embodiments of the strapping device includes a single motor configured to drive both the tensioning assembly and the sealing assembly. In other embodiments, the strapping device includes separate motors configured to drive the respective tensioning and sealing assemblies and may include separate transmissions for each motor.

[0095] Other embodiments of the strapping device may include fewer assemblies, components, and/or features than those included in the strapping device 50 described above and shown in the Figures. In other words, while the strapping device 50 includes all of the assemblies, components, and features described above, they are independent of one another and may be independently included in other strapping devices.

[0096] While the strapping device described above is a handheld strapping device, the strapping device may be any other suitable strapping device in other embodiments, such as a standalone automatic or semi-automatic strapping machine.

Claims

1. A strapping device comprising: a rocker movable between a home position and a strap-insertion position; a rocker mover; a motor operably connected to the rocker mover and configured to move the rocker mover; and a controller operably connected to the motor and configured to control the motor, wherein the controller is configured to, responsive to an opening condition being met: control the motor to begin moving the rocker mover; and responsive to the earlier of a first shut-off condition being met and a tool-opened condition being met, control the motor to stop moving the rocker mover.

2. The strapping device of claim 1, wherein the controller is configured to determine that the tool-opened condition has been met based on feedback from a sensor.

3. The strapping device of claim 2, further comprising the sensor, wherein the sensor is configured to detect the rocker when the rocker reaches the strap-insertion position, wherein the controller is configured to determine that the tool-opened condition has been met when the sensor detects the rocker.

4. The strapping device of claim 2, further comprising the sensor, wherein the sensor is configured to detect a component of the strapping device other than the rocker when the rocker reaches the strap-insertion position, wherein the controller is configured to determine that the tool-opened condition has been met when the sensor detects the component.

5. The strapping device of claim 4, wherein the rocker mover is rotatable and comprises a cam, the strapping device further comprising a cam-engaging finger movable from a first position in which the cam-engaging finger is removed from a rotational path of the cam to a second position in which the cam-engaging finger extends across the rotational path of the cam to a third position in which the cam-engaging finger engages a stop, wherein the cam is positioned such that, when the cam-engaging finger is in the second position, rotation of the rocker mover causes the cam to engage the cam-engaging finger, force the cam-engaging finger to the third position, and thereafter move the rocker from the tensioning position to the strapinsertion position, wherein the component comprises the cam-engaging finger.

6. The strapping device of claim 2, wherein the first shut-off condition is met when the tool-opened condition has not been met before expiration of a designated period.

7. The strapping device of claim 6, wherein the first shut-off condition is met when the tool-opened condition has not been met before expiration of the designated period after the motor begins moving the rocker mover.

8. The strapping device of claim 7, wherein the designated period is a period of time.

9. The strapping device of claim 6, further comprising a body movable between a home position and an actuated position, wherein the controller is configured to determine that the opening condition has been met after the body has moved away from the home position.

10. The strapping device of claim 9, wherein the sensor comprises a first sensor, wherein the body comprises a trigger, the strapping device further comprising a second sensor configured to detect the trigger after the body has moved away from the home position, wherein the controller is configured to determine that the opening condition has been met after the body has moved away from the home position based on feedback from the second sensor.

11. The strapping device of claim 10, wherein the sensor is configured to detect the trigger after the body has moved away from the home position and before the body has reached the actuated position.

12. The strapping device of claim 10, wherein the sensor is configured to detect the trigger when the body reaches the actuated position.

13. The strapping device of claim 1, wherein the first shut-off condition is different from the opening condition.

14. The strapping device of claim 1, further comprising a tensioning wheel, wherein the motor is operably connected to the tensioning wheel and configured to rotate the tensioning wheel, wherein the controller is further configured to, responsive to a tensioning condition being met: control the motor to begin moving the rocker mover and begin rotating the tensioning wheel; and responsive to a second shut-off condition being met while the motor is rotating the tensioning wheel, control the motor to stop rotating the tensioning wheel.

15. The strapping device of claim 14, wherein the second shut-off condition is different from the first shut-off condition.

16. The strapping device of claim 15, wherein the second shut-off condition is different from the opening condition.

17. The strapping device of claim 16, further comprising a body movable between a home position and an actuated position, wherein the controller is configured to determine that the opening condition has been met after the body has moved away from the home position but before the body reaches the actuated position and that the second shut-off condition has been met when the body is moved away from the home position.

18. The strapping device of claim 17, further comprising a sensor configured to detect when the body moves away from the home position.

19. The strapping device of claim 18, wherein the sensor comprises a first sensor, the strapping device further comprising a second sensor configured to detect when the rocker reaches the strap-insertion position.

20. A method of operating a strapping device, the method comprising: determining that an opening condition has been met; responsive to determining that the opening condition has been met, controlling a motor to begin rotating a rocker mover; before a rocker has reached a strap-insertion position, determining that a first shut-off condition has been met; and responsive to determining that the first shut-off condition has been met, controlling the motor to stop rotating the rocker mover.

21 . The method of claim 20, wherein the first shut-off condition is different from the opening condition.

22. The method of claim 21, wherein the first shut-off condition is met when a tool- opened condition is not met before expiration of a designated period.

23. The method of claim 22, wherein the opening condition has been met after a body of the strapping device has moved away from a home position toward an actuated position.

24. The method of claim 21, further comprising determining that the opening condition has been met based on feedback from a first sensor and determining that the first shutoff condition has been met based on feedback from a second sensor.